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䡵 Emissions Inspection And Maintenance
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
䡵 Replacement Parts . . . . . . . . . . . . . . . . . . . . . 507
䡵 Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . 507䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . 508
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 509
▫ Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . 511
▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . 512
▫ Maintenance-Free Battery . . . . . . . . . . . . . . 512
▫ Air Conditioner Maintenance . . . . . . . . . . . . 514
▫ Front Prop Shaft Lubrication – 2500/3500(Four-Wheel Drive) Models . . . . . . . . . . . . . 515
▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . 515500 MAINTAINING YOUR VEHICLE
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . 516
▫ Adding Washer Fluid . . . . . . . . . . . . . . . . . 516
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . 517
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . 520
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . 525
▫ Rear Axle And 4X4 Front Driving Axle FluidLevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
▫ Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 528
▫ Automatic Transmission . . . . . . . . . . . . . . . 528
▫ Appearance Care And Protection FromCorrosion . . . . . . . . . . . . . . . . . . . . . . . . . . 531
䡵 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
▫ Totally Integrated Power Module . . . . . . . . . 536
䡵 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . 541䡵 Replacement Bulbs 䡵 Bulb Replacement
. . . . . . . . . . . . . . . . . . . . 542
. . . . . . . . . . . . . . . . . . . . . 543▫ Dual Or Quad Headlamp/Front Park And
Turn Signal — If Equipped . . . . . . . . . . . . . 543
▫ Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . 545
▫ Rear Tail/Stop, Turn Signal And BackupLamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
▫ Center High-Mounted Stoplamp (CHMSL)
With Cargo Lamp . . . . . . . . . . . . . . . . . . . . 546
▫ Cab Top Clearance Lamps — If Equipped . . . 548
▫ Rear Lamp Bar ID Marker (Dual RearWheels) — If Equipped . . . . . . . . . . . . . . . . 550
▫ Side Marker Lamps (Dual Rear Wheels) —
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . 551
䡵 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . 552
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . 554MAINTAINING YOUR VEHICLE 501
▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 555502 MAINTAINING YOUR VEHICLE ENGINE COMPARTMENT — 3.7L
1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick (If Equipped) 3 — Engine Oil Dipstick 4 — Brake Fluid Reservoir 5 — Battery 6 — Integrated Power Module
7 — Washer Fluid Reservoir 8 — Power Steering Fluid Reservoir 9 — Engine Oil Fill 10 — Coolant Pressure Cap 11 — Engine Coolant Reservoir
ENGINE COMPARTMENT — 4.7L
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1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick 3 — Engine Oil Dipstick 4 — Brake Fluid Reservoir 5 — Battery 6 — Integrated Power Module
7 — Washer Fluid Reservoir 8 — Power Steering Fluid Reservoir 9 — Engine Oil Fill 10 — Coolant Pressure Cap 11 — Engine Coolant Reservoir
504 MAINTAINING YOUR VEHICLE ENGINE COMPARTMENT — 5.7L
1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick 3 — Engine Oil Fill 4 — Engine Oil Dipstick 5 — Brake Fluid Reservoir 6 — Battery
7 — Washer Fluid Reservoir 8 — Integrated Power Module 9 — Power Steering Fluid Reservoir 10 — Coolant Pressure Cap 11 — Engine Coolant Reservoir
ONBOARD DIAGNOSTIC SYSTEM (OBD II) Your vehicle is equipped with a sophisticated onboard diagnostic system called OBDII. This system monitors the performance of the emissions, engine, and automatic transmission control systems. When these systems are operating properly, your vehicle will provide excellent performance and fuel economy, as well as engine emis- sions well within current government regulations. If any of these systems require service, the OBD II system will turn on the Malfunction Indicator Light (MIL). It will also store diagnostic codes and other information to assist your service technician in making repairs. Al- though your vehicle will usually be drivable and not need towing, see your authorized dealer for service as soon as possible.
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CAUTION!
• Prolonged driving with the MIL on could cause further damage to the emission control system. It could also affect fuel economy and drivability. The vehicle must be serviced before any emissions tests can be performed. • If the MIL is flashing, severe catalytic converter damage and power loss will soon occur. Immedi- ate service is required.
Loose Fuel Filler Cap Message
If the vehicle’s diagnostic system determines that the fuel filler cap in loose, improperly installed, or damaged, a “gASCAP” message will be displayed in the instrument cluster. Tighten the gas cap until a “clicking” sound is heard/felt. This is an indication that the gas cap is properly tightened. Press the odometer reset button to turn the message off. If the problem persists, the message
506 MAINTAINING YOUR VEHICLE will appear the next time the vehicle is started. This might indicate a damaged cap. If the problem is detected twice in a row, the system will turn on the MIL. Resolving the problem will turn the MIL light off.
EMISSIONS INSPECTION AND MAINTENANCE PROGRAMS In some localities, it may be a legal requirement to pass an inspection of your vehicle’s emissions control system. Failure to pass could prevent vehicle registration.
For states that require an Inspection and Mainte- nance (I/M), this check verifies the “Malfunction Indicator Light (MIL)” is functioning and is not on when the engine is running, and that the OBD II system is ready for testing. Normally, the OBD II system will be ready. The OBD II system may not be ready if your vehicle was recently
serviced, recently had a dead battery or a battery replace- ment. If the OBD II system should be determined not ready for the I/M test, your vehicle may fail the test. Your vehicle has a simple ignition key-actuated test, which you can use prior to going to the test station. To check if your vehicle’s OBD II system is ready, you must do the following: 1. Turn the ignition switch to the ON position, but do not crank or start the engine. 2. If you crank or start the engine, you will have to start this test over. 3. As soon as you turn the ignition switch to the ON position, you will see the MIL symbol come on as part of a normal bulb check.
4. Approximately 15 seconds later, one of two things will happen:
a. The MIL will flash for about 10 seconds and then return to being fully illuminated until you turn OFF the ignition or start the engine. This means that your vehicle’s OBD II system is not ready and you should not proceed to the I/M station. b. The MIL will not flash at all and will remain fully illuminated until you turn OFF the ignition or start the engine. This means that your vehicle’s OBD II system is ready and you can proceed to the I/M station.
If your OBD II system is not ready, you should see your authorized dealer or repair facility. If your vehicle was recently serviced or had a battery failure or replacement, you may need to do nothing more than drive your vehicle as you normally would in order for your OBD II system to update. A recheck with the above test routine may then indicate that the system is now ready.
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Regardless of whether your vehicle’s OBD II system is ready or not, if the MIL is illuminated during normal vehicle operation you should have your vehicle serviced before going to the I/M station. The I/M station can fail your vehicle because the MIL is on with the engine running.REPLACEMENT PARTS Use of genuine MOPAR威 parts for normal/scheduled maintenance and repairs is highly recommended to en- sure the designed performance. Damage or failures caused by the use of non-MOPAR威 parts for maintenance and repairs will not be covered by the manufacturer’s warranty.
DEALER SERVICE Your authorized dealer has the qualified service person- nel, special tools and equipment to perform all service operations in an expert manner. Service Manuals are available which include detailed service information for
508 MAINTAINING YOUR VEHICLE your vehicle. Refer to these manuals before attempting any procedure yourself. Intentional tampering with emissions control NOTE: systems may void your warranty and could result in civil penalties being assessed against you.
WARNING!
You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.
MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides those maintenance items specified in the fixed maintenance schedule, there are other components which may require servicing or replacement in the future.
CAUTION!
• Failure to properly maintain your vehicle or per- form repairs and service when necessary could result in more costly repairs, damage to other components or negatively impact vehicle perfor- mance. Immediately have potential malfunctions examined by an authorized Chrysler Group LLC dealership or qualified repair center.
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CAUTION! (Continued)
• Your vehicle has been built with improved fluids that protect the performance and durability of your vehicle and also allow extended maintenance intervals. Do not use chemical flushes in these components as the chemicals can damage your engine, transmission, power steering or air condi- tioning. Such damage is not covered by the New Vehicle Limited Warranty. If a flush is needed because of component malfunction, use only the specified fluid for the flushing procedure.
Engine Oil
Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop.
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The best time to check the engine oil level is about five minutes after a fully warmed up engine is shut off. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Always maintain the oil level within the SAFE zone on the dipstick. Adding one quart of oil when the reading is at the bottom of the SAFE zone will result in a reading at the top of the safe zone on these engines.CAUTION!
Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine.
Change Engine Oil The oil change indicator system will remind you that it is time to take your vehicle in for scheduled maintenance. Refer to “Maintenance Schedule” for further information.
510 MAINTAINING YOUR VEHICLE NOTE: Under no circumstances should oil change intervals exceed 6,000 miles (10 000 km) or six months, whichever occurs first.
Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API Certified and meet the requirements of Chrysler Material Standard MS-6395. American Petroleum Institute (API) Engine Oil Identification Symbol
This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacturer only recommends API Certified engine oils.
CAUTION!
Do not use chemical flushes in your engine oil as the chemicals can damage your engine. Such damage is not covered by the New Vehicle Limited Warranty.
Engine Oil Viscosity (SAE Grade) SAE 5W-20 engine oil is recommended for all operating temperatures. This engine oil improves low temperature starting and vehicle fuel economy. The engine oil filler cap also shows the recommended engine oil viscosity for your engine. For information on engine oil filler cap location, refer to “Engine Compartment” in “Maintaining Your Vehicle” for further information. NOTE: Vehicles equipped with a 5.7L engine must use SAE 5W-20 oil. Failure to do so may result in improper operation of the Multi-Displacement System (MDS). Re- fer to “Multi-Displacement System” in “Starting and Operating” for further information.
Lubricants which do not have both the engine oil certi- fication mark and the correct SAE viscosity grade num- ber should not be used. NOTE: For 2500/3500 trucks with a 5.7L engine oper- ating under a gross combined weight rating of 14,000 lbs (6 350 kg) or greater, SAE 5W-30 engine oil is recom- mended for all operating temperatures. Synthetic Engine Oils You may use synthetic engine oils if the recommended oil quality requirements are met and the recommended maintenance intervals for oil and filter changes are followed. Materials Added to Engine Oil The manufacturer strongly recommends against the ad- dition of any additives (other than leak detection dyes) to the engine oil. Engine oil is an engineered product and its performance may be impaired by supplemental additives.
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Disposing of Used Engine Oil and Oil Filters Care should be taken in disposing of used engine oil and oil filters from your vehicle. Used oil and oil filters, indiscriminately discarded, can present a problem to the environment. Contact your authorized dealer, service station or governmental agency for advice on how and where used oil and oil filters can be safely discarded in your area. Engine Oil Filter The engine oil filter should be replaced at every engine oil change. Engine Oil Filter Selection The manufacturer’s engines have a full-flow type oil filter. Use a filter of this type for replacement. The quality of replacement filters varies considerably. Only high- quality filters should be used to assure most efficient service. MOPAR威 engine oil filters are a high-quality oil filter and are recommended.
512 MAINTAINING YOUR VEHICLE Engine Air Cleaner Filter Refer to “Maintenance Schedule” for further information.
WARNING!
The air induction system (air cleaner, hoses, etc.) can provide a measure of protection in the case of engine backfire. Do not remove the air induction system (air cleaner, hoses, etc.) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air induction system (air cleaner, hoses, etc.) removed. Failure to do so can result in serious personal injury.
Engine Air Cleaner Filter Selection The quality of replacement engine air cleaner filters varies considerably. Only high quality filters should be
used to assure most efficient service. MOPAR威 engine air cleaner filters are a high quality filter and are recommended. Maintenance-Free Battery The top of the maintenance-free battery is permanently sealed. You will never have to add water or is periodic maintenance required.
WARNING!
• Battery fluid is a corrosive acid solution and can burn or even blind you. Do not allow battery fluid to contact your eyes, skin or clothing. Do not lean over a battery when attaching clamps. If acid splashes in your eyes or on your skin, flush the area immediately with large amounts of water.
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WARNING! (Continued)
• Battery gas is flammable and explosive. Keep flame or sparks away from the battery. Do not use a booster battery or any other booster source with an output greater than 12 volts. Do not allow cable clamps to touch each other. • Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
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CAUTION!
• It is essential when replacing the cables on the battery that the positive cable is attached to the positive post and the negative cable is attached to the negative post. Battery posts are marked (+) positive and (-) negative and are identified on the battery case. • If a “fast charger” is used while the battery is in the vehicle, disconnect both vehicle battery cables before connecting the charger to the battery. Do not use a “fast charger” to provide starting voltage.
514 MAINTAINING YOUR VEHICLE Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an authorized dealer at the start of each warm season. This service should include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.
CAUTION!
Do not use chemical flushes in your air conditioning system as the chemicals can damage your air condi- tioning components. Such damage is not covered by the New Vehicle Limited Warranty.
WARNING!
• Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. Refer to Warranty Information Book, located on the DVD, for further warranty information. • The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
NOTE: Use only manufacturer approved A/C System Sealers, Stop Leak Products, Seal Conditioners, Compres- sor Oil, or Refrigerants.
Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant is a hydrofluoro- carbon (HFC) that is endorsed by the Environmental Protection Agency (EPA) and is an ozone-saving product. However, the manufacturer recommends that air condi- tioning service be performed by authorized dealers or other service facilities using recovery and recycling equipment. Front Prop Shaft Lubrication – 2500/3500
(Four-Wheel Drive) Models Lubricate the front driveshaft grease fitting at each oil change. Refer to “Maintenance Schedule” for further information. Use MOPAR威 Type MS-6560 (lithium-based grease), or equivalent. Body Lubrication Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers, liftgate,MAINTAINING YOUR VEHICLE 515
tailgate, sliding doors and hood hinges, should be lubri- cated periodically with a lithium based grease, such as MOPAR威 Spray White Lube or equivalent, to assure quiet, easy operation and to protect against rust and wear. Prior to the application of any lubricant, the parts concerned should be wiped clean to remove dust and grit. After lubricating, excess oil and grease should be removed. Particular attention should also be given to hood latching components to ensure proper function. When performing other underhood services, the hood latch, release mechanism and safety catch should be cleaned and lubricated. The external lock cylinders should be lubricated twice a year, preferably in the Fall and Spring. Apply a small amount of a high quality lubricant, such as MOPAR威 Lock Cylinder Lubricant or equivalent directly into the lock cylinder.516 MAINTAINING YOUR VEHICLE Windshield Wiper Blades Clean the rubber edges of the wiper blades and the windshield periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accumula- tions of salt or road film. Operation of the wipers on dry glass for long periods may cause deterioration of the wiper blades. Always use washer fluid when using the wipers to remove salt or dirt from a dry windshield. Avoid using the wiper blades to remove frost or ice from the windshield. Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc. NOTE: Life expectancy of wiper blades varies depend- ing on geographical area and frequency of use. Poor performance of blades may be present with chattering, marks, water lines or wet spots. If any condition is
present please proceed to clean wiper blades with humid cloth removing any debris that may be affecting its function. Adding Washer Fluid The fluid reservoir is located under the hood and should be checked for fluid level at regular intervals. Fill the reservoir with windshield washer solvent only (not ra- diator antifreeze). When refilling the washer fluid reser- voir, take some washer fluid and apply it to a cloth or towel and wipe the wiper blades clean. This will help blade performance. To prevent freeze-up of your windshield washer system in cold weather, select a solution or mixture that meets or exceeds the temperature range of your climate. This rating information can be found on most washer fluid containers. The washer fluid reservoir will hold a full gallon of fluid when the Low Washer Fluid Light illuminates.
WARNING!
Commercially available windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution.
After the engine has warmed up, operate the defroster for a few minutes to reduce the possibility of smearing or freezing the fluid on the cold windshield. Windshield washer solution used with water as directed on the container, aids cleaning action, reduces the freezing point to avoid line clogging, and is not harmful to paint or trim. Exhaust System The best protection against carbon monoxide entry into the vehicle body is a properly maintained engine exhaust system.
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Whenever a change is noticed in the sound of the exhaust system, when exhaust fumes can be detected inside the vehicle or when the underside or rear of the vehicle is damaged, have a competent mechanic inspect the com- plete exhaust system and adjacent body areas for broken, damaged, deteriorated, or mispositioned parts. Open seams or loose connections could permit exhaust fumes to seep into the passenger compartment. In addition, inspect the exhaust system each time the vehicle is raised for lubrication or oil change. Replace as required.518 MAINTAINING YOUR VEHICLE
WARNING!
Exhaust gases can injure or kill. They contain carbon monoxide (CO) which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. To avoid breathing CO, refer to “Safety Tips/Exhaust Gas” in “Things To Know Before Starting Your Vehicle” for further informa- tion.
CAUTION!
The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effective- ness of the catalyst as an emissions control device and may seriously reduce engine performance and cause serious damage to the engine.
Under normal operating conditions, the catalytic con- verter will not require maintenance. However, it is im- portant to keep the engine properly tuned to assure proper catalyst operation and prevent possible catalyst damage.
CAUTION!
Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involv- ing engine misfire or other apparent loss of perfor- mance, have your vehicle serviced promptly. Contin- ued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and the vehicle.
NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
WARNING!
A hot exhaust system can start a fire if you park over materials that can burn. Such materials might be grass or leaves coming into contact with your exhaust system. Do not park or operate your vehicle in areas where your exhaust system can contact anything that can burn.
In unusual situations involving grossly malfunctioning engine operation, a scorching odor may indicate severe and abnormal catalyst overheating. If this occurs, the vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Thereafter, service, including a tune-up to manufacturer’s specifications, should be ob- tained immediately.
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To minimize the possibility of catalyst damage: • Do not shut off the engine or interrupt the ignition when the transmission is in gear and the vehicle is in motion. • Do not try to start the engine by pushing or towing the • Do not idle the engine with any spark plug wires disconnected or removed, such as when diagnostic testing or for prolonged periods during very rough idling or malfunctioning operating conditions.
vehicle.
520 MAINTAINING YOUR VEHICLE Cooling System
WARNING!
You or others can be badly burned by hot coolant or steam from your radiator. If you see or hear steam coming from under the hood, do not open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radiator is hot.
Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12 months (before the onset of freezing weather, where applicable). If the engine coolant (antifreeze) is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh coolant. Check the front of the A/C condenser for any accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the condenser.
Check the coolant recovery bottle tubing for brittle rub- ber, cracking, tears, cuts and tightness of the connection at the bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the cooling system pressure cap for proper vacuum sealing by draining a small amount of engine coolant (antifreeze) from the radiator drain cock. If the cap is sealing properly, the engine coolant (anti- freeze) will begin to drain from the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT. Cooling System – Drain, Flush and Refill If the engine coolant (antifreeze) is dirty or contains a considerable amount of sediment, clean and flush with a reliable cooling system cleaner. Follow with a thorough rinsing to remove all deposits and chemicals. Properly dispose of old engine coolant (antifreeze) solution.
Refer to “Maintenance Schedule” for further information. Selection Of Coolant Use only the manufacturer’s recommended engine cool- ant (antifreeze). Refer to “Fluids, Lubricants, and Genu- ine Parts” in “Maintaining Your Vehicle” for further information.
CAUTION!
• Mixing of engine coolant (antifreeze) other than specified HOAT engine coolant (antifreeze), may result in engine damage and may decrease corro- sion protection. If a non-HOAT engine coolant (antifreeze) is introduced into the cooling system in an emergency, it should be replaced with the specified engine coolant (antifreeze) as soon as possible.
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CAUTION! (Continued)
• Do not use water alone or alcohol-based engine coolant (antifreeze) products. Do not use addi- tional rust inhibitors or antirust products, as they may not be compatible with the engine coolant (antifreeze) and may plug the radiator. • This vehicle has not been designed for use with Propylene Glycol based engine coolant (anti- freeze). Use of Propylene Glycol based engine coolant (antifreeze) is not recommended.
Adding Coolant Your vehicle has been built with an improved engine coolant (antifreeze) that allows extended maintenance intervals. This engine coolant (antifreeze) can be used up to 5 Years or 102,000 miles (170 000 km) before replace- ment. To prevent reducing this extended maintenance period, it is important that you use the same engine coolant (antifreeze) throughout the life of your vehicle.
522 MAINTAINING YOUR VEHICLE Please review these recommendations for using Hybrid Organic Additive Technology (HOAT) engine coolant (antifreeze). When adding engine coolant (antifreeze): • The manufacturer
recommends using MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. • Mix a minimum solution of 50% HOAT engine coolant (antifreeze) and distilled water. Use higher concentra- tions (not to exceed 70%) if temperatures below -34°F (-37°C) are anticipated. • Use only high purity water such as distilled or deion- ized water when mixing the water/engine coolant (antifreeze) solution. The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system.
Please note that it is the owner’s responsibility to main- tain the proper level of protection against freezing ac- cording to the temperatures occurring in the area where the vehicle is operated. NOTE: Mixing engine coolant (antifreeze) types will decrease the life of the engine coolant (antifreeze) and will require more frequent engine coolant (antifreeze) changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of engine coolant (antifreeze), and to ensure that the engine coolant (antifreeze) will return to the radiator from the coolant recovery bottle. The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
WARNING!
• The warning words “DO NOT OPEN HOT” on the cooling system pressure cap are a safety precaution. Never add engine coolant (antifreeze) when the engine is overheated. Do not loosen or remove the cap to cool an overheated engine. Heat causes pres- sure to build up in the cooling system. To prevent scalding or injury, do not remove the pressure cap while the system is hot or under pressure. • Do not use a pressure cap other than the one specified for your vehicle. Personal injury or en- gine damage may result.
Disposal of Used Coolant Used ethylene glycol-based engine coolant (antifreeze) is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. To prevent ingestion by ani- mals or children do not store ethylene glycol-based
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engine coolant (antifreeze) in open containers or allow it to remain in puddles on the ground. If ingested by a child or pet, seek emergency assistance immediately. Clean up any ground spills immediately. Coolant Level The coolant bottle provides a quick visual method for determining that the coolant level is adequate. With the engine cold, the level of the engine coolant (antifreeze) in the coolant recovery bottle should be between the ranges indicated on the bottle. The radiator normally remains completely full, so there is no need to remove the radiator cap unless checking for engine coolant (antifreeze) freeze point or replacing en- gine coolant (antifreeze). Advise your service attendant of this. As long as the engine operating temperature is satisfactory, the coolant bottle need only be checked once a month.524 MAINTAINING YOUR VEHICLE When additional engine coolant (antifreeze) is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points to Remember NOTE: When the vehicle is stopped after a few miles (a few kilometers) of operation, you may observe vapor coming from the front of the engine compartment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vapor- ized when the thermostat opens, allowing hot coolant to enter the radiator. If an examination of your engine compartment shows no evidence of radiator or hose leaks, the vehicle may be safely driven. The vapor will soon dissipate. • Do not overfill the coolant recovery bottle. • Check engine coolant (antifreeze) freeze point in the radiator and in the coolant recovery bottle. If engine
coolant (antifreeze) needs to be added, contents of coolant recovery bottle must also be protected against freezing. • If frequent engine coolant (antifreeze) additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pressure tested for leaks. • Maintain engine coolant (antifreeze) concentration at 50% HOAT engine coolant (antifreeze) (minimum) and distilled water for proper corrosion protection of your engine, which contains aluminum components. • Make sure that the radiator and coolant recovery bottle overflow hoses are not kinked or obstructed. • Keep the front of the radiator clean. If your vehicle is equipped with air conditioning, keep the front of the condenser clean, also.
• Do not change the thermostat for Summer or Winter operation. If replacement is ever necessary, install ONLY the correct type thermostat. Other designs may result in unsatisfactory engine coolant (antifreeze) performance, poor gas mileage, and increased emissions.
Brake System In order to assure brake system performance, all brake system components should be inspected periodically. Refer to “Maintenance Schedule” for further information.
WARNING!
Riding the brakes can lead to brake failure and possibly an accident. Driving with your foot resting or riding on the brake pedal can result in abnormally high brake temperatures, excessive lining wear, and possible brake damage. You would not have your full braking capacity in an emergency.
MAINTAINING YOUR VEHICLE 525
Brake Fluid Level Check The fluid level of the master cylinder should be checked when performing under the hood service or immediately if the brake system warning lamp indicates system failure. The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a “MAX” dot and an “MIN” dot. The fluid level must be kept within these two dots. Do not add fluid above the MAX mark because leakage may occur at the cap. With disc brakes the fluid level can be expected to fall as the brake linings wear. However, an unexpected drop in fluid level may be caused by a leak and a system check should be conducted. Use only the manufacturer’s recommended brake fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information.
526 MAINTAINING YOUR VEHICLE
WARNING!
• Use only manufacturer’s recommended brake fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. Using the wrong type of brake fluid can severely damage your brake system and/or impair its performance. The proper type of brake fluid for your vehicle is also labeled on the origi- nal factory installed hydraulic master cylinder reservoir.
(Continued)
WARNING! (Continued)
• To avoid contamination from foreign matter or moisture, use only new brake fluid or fluid that has been in a tightly closed container. Keep the master cylinder reservoir cap secured at all times. Brake fluid in a open container absorbs moisture from the air resulting in a lower boiling point. This may cause it to boil unexpectedly during hard or prolonged braking, resulting in sudden brake failure. This could result in a accident. • Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts, causing the brake fluid to catch fire. Brake fluid can also damage painted and vinyl surfaces, care should be taken to avoid its contact with these surfaces.
(Continued)
WARNING! (Continued)
• Do not allow petroleum based fluid to contami- nate the brake fluid. Brake seal components could be damaged, causing partial or complete brake failure. This could result in an accident.
Rear Axle And 4x4 Front Driving Axle Fluid Level For normal service, periodic fluid level checks are not required. When the vehicle is serviced for other reasons the exterior surfaces of the axle assembly should be inspected. If gear oil leakage is suspected inspect the fluid level. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further informa- tion. This inspection should be made with the vehicle in a level position. The fluid level should be even with the bottom of the fill hole for the manufacturer’s C205F HD front
MAINTAINING YOUR VEHICLE 527
axles. The fluid level should be 5/8 in (16 mm) below the fill hole on 9 1/4 in manufacturer’s rear axles. For all 2500/3500 Model axles, the fluid level should be 1/4” ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole on the 9.25 in front and 3/4 in ± 1/4 in (19 mm ± 6.4 mm) on 10.5 in rear axles. The 11.5 in rear axle level should be 1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole. Drain and Refill Refer to “Maintenance Schedule” for further information. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. NOTE: The presence of water in the gear lubricant will result in corrosion and possible failure of differential components. Operation of the vehicle in water, as may be encountered in some off-highway types of service, will require draining and refilling the axle to avoid damage.528 MAINTAINING YOUR VEHICLE Limited-Slip Differentials This vehicle requires that 4 oz. (118 ml) MOPAR威 Limited Slip Additive or equiva- lent be added to the gear lubricant. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. The MOPAR威 Limited Slip Additive or equivalent should be added to the gear lubricant whenever a fluid change is made. 2500/3500 Model Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers). Transfer Case
Drain and Refill Refer to “Maintenance Schedule” for further information. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information.
Fluid Level Check This fluid level can be checked by removing the filler plug. The fluid level should be to the bottom edge of the filler plug hole with the vehicle in a level position. Automatic Transmission
Selection Of Lubricant It is important that the proper lubricant is used in the transmission to assure optimum transmission perfor- mance. Use only the manufacturer’s recommended trans- mission fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further informa- tion. It is important that the transmission fluid be main- tained at the prescribed level using the recommended fluid.
CAUTION!
• Do not use chemical flushes in your transmission as the chemicals can damage your transmission components. Such damage is not covered by the New Vehicle Limited Warranty. • Using a transmission fluid other than the manu- facturer’s recommended fluid may cause deterio- ration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturer’s recommended fluid will result in more frequent fluid and filter changes. Refer to “Fluids, Lubricants, and Genu- ine Parts” in “Maintaining Your Vehicle” for fur- ther information.
Fluid Level Check If equipped with a dipstick, use the following procedure. If your vehicle has a capped dipstick tube, it is sealed and
MAINTAINING YOUR VEHICLE 529
should not be tampered with. Your authorized dealer has the proper tools to ensure that the fluid level is set properly. The fluid level should be checked when the engine is fully warmed up and the fluid in the transmis- sion is at normal operating temperature. Operation of the transmission with an improper fluid level will greatly reduce the life of the transmission and of the fluid. Check the fluid level whenever the vehicle is serviced. Fluid Level Check – 42RLE/545RFE Check the fluid level while the transmission is at normal operating temperature 82°C (180°F). This occurs after at least 15 miles (25 km) of driving. At normal operating temperature the fluid cannot be held comfortably be- tween the fingertips. To check the automatic transmission fluid level properly, the following procedure must be used: 1. Operate the engine at idle speed and normal operating temperature.530 MAINTAINING YOUR VEHICLE 2. The vehicle must be on level ground. 3. Fully apply the parking brake and press the brake pedal. 4. Place the shift lever momentarily into each gear posi- tion ending with the lever in PARK. 5. Remove the dipstick, wipe it clean and reinsert it until seated. 6. Remove the dipstick again and note the fluid level on both sides. The fluid level should be between the “HOT” (upper) reference holes on the dipstick at normal operat- ing temperature. Verify that solid coating of oil is seen on both sides of the dipstick. If the fluid is low, add as required into the dipstick tube. Do not overfill. After adding any quantity of oil through the oil fill tube, wait a minimum of two minutes for the oil to fully drain into the transmission before rechecking the fluid level.
If it is necessary to check the transmission below NOTE: the operating temperature, the fluid level should be between the two “COLD” (lower) holes on the dipstick with the fluid at approximately 70°F (21°C) (room tem- perature). If the fluid level is correctly established at room temperature, it should be between the “HOT” (upper) reference holes when the transmission reaches 180°F (82°C). Remember it is best to check the level at the normal operating temperature.
CAUTION!
Be aware that if the fluid temperature is below 50°F (10°C) it may not register on the dipstick. Do not add fluid until the temperature is elevated enough to produce an accurate reading.
7. Check for leaks. Release parking brake.
To prevent dirt and water from entering the transmission after checking or replenishing fluid, make certain that the dipstick cap is properly reseated. It is normal for the dipstick cap to spring back slightly from its fully seated position, as long as its seal remains engaged in the dipstick tube. Automatic Transmission Fluid and Filter Change Refer to “Maintenance Schedule” or further information. If the transmission is disassembled for any NOTE: reason, the fluid and filter(s) should be changed. It is important that proper lubricant is used in the transmission. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information.
MAINTAINING YOUR VEHICLE 531
Special Additives Automatic Transmission Fluid (ATF) is an engineered product and its performance may be impaired by supple- mental additives. Therefore, do not add any fluid addi- tives to the transmission. The only exception to this policy is the use of special dyes to aid in detecting fluid leaks. In addition, avoid using transmission sealers as they may adversely affect seals. Appearance Care and Protection from Corrosion
Protection of Body and Paint from Corrosion Vehicle body care requirements vary according to geo- graphic locations and usage. Chemicals that make roads passable in snow and ice, and those that are sprayed on trees and road surfaces during other seasons, are highly corrosive to the metal in your vehicle. Outside parking, which exposes your vehicle to airborne contaminants, road surfaces on which the vehicle is operated, extreme
532 MAINTAINING YOUR VEHICLE hot or cold weather and other extreme conditions will have an adverse affect on paint, metal trim, and under- body protection. The following maintenance recommendations will enable you to obtain maximum benefit from the corrosion resistance built into your vehicle. What Causes Corrosion? Corrosion is the result of deterioration or removal of paint and protective coatings from your vehicle. The most common causes are: • Road salt, dirt and moisture accumulation. • Stone and gravel impact. • Insects, tree sap and tar. • Salt in the air near seacoast localities. • Atmospheric fallout/industrial pollutants.
Washing • Wash your vehicle regularly. Always wash your ve- hicle in the shade using MOPAR威 Car Wash or equiva- lent, or a mild car wash soap and rinse the panels completely with clear water. • If insects, tar or other similar deposits have accumu- lated on your vehicle, use MOPAR威 Super Kleen Bug and Tar Remover or equivalent to remove. • Use a high quality cleaner wax, such as MOPAR威 Cleaner Wax or equivalent to remove road film, stains and to protect your paint finish. Take care never to scratch the paint. • Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder which will scratch metal and painted surfaces.
Special Care • If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month. • It is important that the drain holes in the lower edges of the doors, rocker panels and trunk be kept clear and open. • If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner.
MAINTAINING YOUR VEHICLE 533
• If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating, have your vehicle repaired as soon as pos- sible. The cost of such repairs is considered the respon- sibility of the owner. • If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed. • If a lot of driving is done on gravel roads, consider • Use MOPAR威 Touch Up Paint or equivalent on scratches as soon as possible. Your authorized dealer has touch up paint to match the color of your vehicle.
mud or stone shields behind each wheel.
Wheel and Wheel Trim Care All wheels and wheel trim, especially aluminum and chrome-plated wheels should be cleaned regularly with a mild soap and water to prevent corrosion. To remove
534 MAINTAINING YOUR VEHICLE heavy soil and/or excessive brake dust, use MOPAR威 Wheel Cleaner or equivalent or select a nonabrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush, or metal polishes. Only MOPAR威 or equivalent is recommended. Do not use oven cleaner. Avoid automatic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective finish. Stain Repel Fabric Cleaning Procedure – If Equipped Stain Repel seats may be cleaned in the following man- ner: • Remove as much of the stain as possible by blotting • Blot any remaining stain with a clean, damp towel.
with a clean, dry towel.
• For tough stains, apply MOPAR威 Total Clean or equivalent, or a mild soap solution to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. • For grease stains, apply MOPAR威 Multi-Purpose Cleaner or equivalent to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. • Do not use any harsh solvents or any other form of
protectants on Stain Repel products.
Interior Care Use MOPAR威 Total Clean or equivalent to clean fabric upholstery and carpeting. Use MOPAR威 Total Clean or equivalent to clean vinyl upholstery. MOPAR威 Total Clean or equivalent is specifically recom- mended for leather upholstery.
Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and MOPAR威 Total Clean or equivalent. Care should be taken to avoid soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, detergents, or ammonia-based cleaners to clean your leather upholstery. Application of a leather condi- tioner is not required to maintain the original condition.
WARNING!
Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.
MAINTAINING YOUR VEHICLE 535
Cleaning Headlights Your vehicle is equipped with plastic headlights and fog lights (if equipped) that are lighter and less susceptible to stone breakage than glass headlights. Plastic is not as scratch resistant as glass and therefore different lens cleaning procedures must be followed. To minimize the possibility of scratching the lenses and reducing light output, avoid wiping with a dry cloth. To remove road dirt, wash with a mild soap solution fol- lowed by rinsing. Do not use abrasive cleaning components, solvents, steel wool or other aggressive material to clean the lenses. Glass Surfaces All glass surfaces should be cleaned on a regular basis with MOPAR威 Glass Cleaner or any commercial household-type glass cleaner. Never use an abrasive type
536 MAINTAINING YOUR VEHICLE cleaner. Use caution when cleaning the inside rear win- dow equipped with electric defrosters or the right rear quarter window equipped with the radio antenna. Do not use scrapers or other sharp instruments which may scratch the elements. When cleaning the rearview mirror, spray cleaner on the towel or rag that you are using. Do not spray cleaner directly on the mirror. Cleaning Plastic Instrument Cluster Lenses The lenses in front of the instruments in this vehicle are molded in clear plastic. When cleaning the lenses, care must be taken to avoid scratching the plastic. 1. Clean with a wet soft rag. A mild soap solution may be used, but do not use high alcohol content or abrasive cleaners. If soap is used, wipe clean with a clean damp rag. 2. Dry with a soft tissue.
Seat Belt Maintenance Do not bleach, dye or clean the belts with chemical solvents or abrasive cleaners. This will weaken the fabric. Sun damage can also weaken the fabric. If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the car to wash them. Replace the belts if they appear frayed or worn or if the buckles do not work properly. Dry with a soft tissue.
FUSES
Totally Integrated Power Module The totally integrated power module (TIPM) is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside
cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart.
Totally Integrated Power Module (TIPM)
Cavity Cartridge
J01
J02
J03
J04
J05
J06
J07
J08
Fuse 30 Amp Pink 30 Amp Pink 25 Amp Natural 40 Amp Green 30 Amp Pink 30 Amp Pink
25 Amp Natural 30 Amp Pink
MAINTAINING YOUR VEHICLE 537
Mini Fuse
Description
Bat – Presafe #1
Bat – Trailer Tow Main Bat – Passenger Door Node Bat – ABS Pump
Bat – ABS Valve
Bat – H/Lamp Wash/ MTV/CM2200/Elec Vac Pump Bat – Driver Door Node Bat – DTCM/Axle Locks
538 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse 30 Amp Pink 40 Amp Green 30 Amp Pink
40 Amp Green 60 Amp Yellow 40 Amp Green 60 Amp Yellow 40 Amp Green
Mini Fuse
Description
Cavity Cartridge
Fuse
Bat – Plg/Electric Brake Bat – L/Bar/Off-Road
Bat – Sway/ Thatchum/Rear Doors Starter Solenoid
Bat – Rad Fan #1/#2/ SSR Bat – Folding Seat/ PZEV Bat – IOD Main
Frt HVAC Motor
M17
M18
M19
M20
M21
M22
M23
M24
Mini Fuse 25 Amp Natural 25 Amp Natural 5 Amp Tan
25 Amp Natural 25 Amp Natural 20 Amp Yellow 20 Amp Yellow 20 Amp Yellow
Description
Bat – Sunroof/ Skylight TCM/Trans Range
Ign R/ACC – Sunroof/Window Sw Illum Frt Wiper
Door Locks
Fuel Pump
Bat – Trlr Light/Pre- Safe #2
Bat – Trlr Tow BUX/ HGMJ09
J10
J11
J12
J13
J14
J15
J16
Cavity Cartridge
Fuse
M25
M26
M27
M28
M29
M30
M31
M32
Mini Fuse 10 Amp Red 10 Amp Red 15 Amp Blue 10 Amp Red
15 Amp Blue 25 Amp Natural 20 Amp Yellow 20 Amp Yellow
Description
Cavity Cartridge
Fuse
Bat – J1962 Diag/ Mirrors Bat – Ign Sw, WIN, PASS Bat – CHMSL/Brake Sw Bat – Corax TPM/ PEM/HVAC Htr Pump Bat – Folding Mirror
Bat – Inverter
Bat – Pwr Out #1
Fr/Rr Washer
M33
M34
M35
M36
M37
M38
M39
M40
MAINTAINING YOUR VEHICLE 539
Mini Fuse 15 Amp Blue 15 Amp Blue 20 Amp Yellow 20 Amp Yellow 10 Amp Red 20 Amp Yellow 30 Amp Green 25 Amp Natural
Description
Bat – NGC/EATX/ PCM Bat – CCN/Interior Light/SCM/Sw Bank Ign R-Frt Seat/Vent
Ign R-Rear Seat/Steer Wheel Horn #1
IOD-CCN/Interior Mods IOD-Amp/Radio
Rear Wiper
540 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse
M41
M42
M43
M44
M45
M46
M47
Mini Fuse 15 Amp Blue
10 Amp Red 10 Amp Red 10 Amp Red 10 Amp Red 20 Amp Yellow 10 Amp Red
Description
Cavity Cartridge
Fuse
IOD-SDARS/VES 2–3/DVD/HFM/ UGDO/Vanity Lamp IOD-HVAC, U/Hood Lamp Horn #2
IGN R/S-ORC/OCM
IGN R-ORC/Trail Tow (BUX) Sense IGN R-Trail Tow (BUX) IGN R-H/Lamp Wash/HVAC/Park Assist/Ir Sns
M48
M49
M50
M51
M52
M53
M54
Mini Fuse 20 Amp Yellow 20 Amp Yellow 25 Amp Natural 20 Amp Yellow 10 Amp Red 15 Amp Blue
20 Amp Yellow
Description
IGN R/ACC-Pwr Outlet #2
IGN R/ACC/Bat-Pwr Outlet #3
ASD #1, #2ASD #3
IGN R/S-SWAY/ TCASE/DTCM/FAD IGN R/S-MFSW/ CNN/SCM/TPM/RR View IOD – Spare
CAUTION!
• When installing the totally integrated power mod- ule cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the totally integrated power module and possibly result in a electrical system failure. • When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system over- load. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected.
MAINTAINING YOUR VEHICLE 541
VEHICLE STORAGE If you are storing your vehicle for more than 21 days, we recommend that you take the following steps to mini- mize the drain on your vehicle’s battery: • Disconnect the Ignition-Off Draw (IOD) fuse located in the Integrated Power Module, located in the engine compartment. The IOD cavity includes a snap-in re- tainer that allows the fuse to be disconnected without removing it from the fuse block. • As an alternative to the above steps you may discon- • Any time you store your vehicle or keep it out of service (i.e., vacation) for two weeks or more, run the air conditioning system at idle for about five minutes in the fresh air and high blower setting. This will ensure adequate system lubrication to minimize the possibility of compressor damage when the system is started again.
nect the negative cables from both batteries.
542 MAINTAINING YOUR VEHICLE NOTE: • When reinstalling the IOD fuse push firmly until fully seated; the gauges in the instrument cluster will do a full sweep when the ignition switch is turned to the RUN position. This is a normal condition. • When the vehicle is shipped from the factory, the IOD fuse is in the up or extracted position. If the radio, interior lamps, keyless entry or other features do not work with the key OFF, check the position of the fuse (or check to see if the fuse is blown) to ensure that it is fully seated. When the IOD fuse is extracted, the instrument cluster in the odometer window will dis- play ⬙NO FUSE.”
REPLACEMENT BULBS
LIGHT BULBS – Interior Bulb No. Overhead Console Lamps . . . . . . . . . . . . . . . TS 212-2
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679NOTE: For lighted switches, see your authorized dealer for replacement instructions. All of the inside bulbs are brass or glass-wedge base. Aluminum base bulbs are not approved. LIGHT BULBS – Exterior Bulb No. Backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 921
Center High Mounted Stop Lamp (CHMSL) . . . . . 921
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9145
Dual Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . H13
Quad Headlamp – Low Beam . . . . . . . . . . . . . . . H11
Quad Headlamp – High Beam . . . . . . . . . . . . . . 9005
Side Marker (Dual Headlamp) . . . . . . . . . . . . . 3157K Side Marker (Quad Headlamp). . . . . . . . . . . . 3157NA Rear License Plate Lamp . . . . . . . . . . . . . . . . . . . 194
Rear Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . 921
Rear Tail/Turn and Stop. . . . . . . . . . . . . . . . . . 3157K Cab Roof Marker Lamps . . . . . . . . . . . . . . . . . 194NA Rear Lamp Bar ID Marker Lamp. . . . . . . . . . . . . . 194
Side Marker Lamps (Dual Rear Wheels) . . . . . . . . 194BULB REPLACEMENT
Dual or Quad Headlamp/Front Park and Turn Signal — If Equipped
1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. Remove the four plastic push-in fasteners that secure the upper radiator seal to the grille support and both fender ledges. 4. Remove the two plastic push-in rivets that secure the upper radiator seal to the radiator. 5. Remove the upper radiator seal from the vehicle. 6. Remove the two headlamp assembly attachment screws.
MAINTAINING YOUR VEHICLE 543
7. Reach into the front wheel house ahead of the front wheel, remove the fastener, and lift the cover over the access hole in the front of the wheel house splash shield. Access to the rear of the lamp can be gained through this access hole.
544 MAINTAINING YOUR VEHICLE 8. Reach through the access hole of the wheel house splash shield and lift the slide lock upward far enough to disengage it from the lock post on the back of the front lamp unit housing.
9. Remove the headlamp assembly. Grasp the outboard edge of the lamp and pull it straight forward to disen- gage the ball stud from the plastic grommet.
10. Disconnect the wiring harness connectors from the bulb socket. 11. Replace bulb(s) as necessary.
CAUTION!
• Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. • Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the bulb socket, or the lamp wiring.
NOTE: There are access covers over both headlamp bulb access holes in the quad front lamp unit housing (if equipped). These covers MUST be reinstalled after the bulb has been replaced.
Fog Lamps
1. Reach under and behind the front bumper to access the back of the front fog lamp housing. 2. Disconnect the fog lamp wiring harness connector from the fog lamp bulb. 3. Rotate the bulb counterclockwise 1⁄4 turn to unlock the bulb from the housing. 4. Pull the bulb straight out from the housing.
CAUTION!
Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.
MAINTAINING YOUR VEHICLE 545
Rear Tail/Stop, Turn Signal and Backup Lamps
1. Remove the two screws that pass through the bed sheetmetal.
546 MAINTAINING YOUR VEHICLE 2. Pull the outboard side of the lamp rearward far enough to unsnap the two receptacles on the outboard side of the lamp housing from the two plastic snap post retainers in the outer box side panel.
3. Disconnect the wiring harness connectors from the bulb socket.
4. Rotate the bulb socket counterclockwise 1/4 turn to unlock it from the housing. 5. Pull the bulb straight out of the socket.
CAUTION!
Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.
6. Reverse the procedure to install the bulb and housing. Center High-Mounted Stoplamp (CHMSL) With Cargo Lamp
1. Remove the two screws holding the housing/lens to the body as shown.
MAINTAINING YOUR VEHICLE 547
2. Separate the connector holding the housing and wir- ing harness to the body.
3. Turn the desired bulb socket 1⁄4 turn and remove the socket and bulb from housing.
548 MAINTAINING YOUR VEHICLE 4. Pull the desired bulb straight from the socket.
• Outside Bulbs: Cargo Lamps • Inside Bulb: Center High-Mounted Stop Lamp 5. Reverse the procedure for installation of bulbs and housing. Cab Top Clearance Lamps — If Equipped
1. Remove the two screws from the top of the lamp.
CAUTION!
Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.
2. Rotate the socket 1⁄4 turn and pull it from the lamp assembly.
3. Pull the bulb straight from it’s socket and replace.
MAINTAINING YOUR VEHICLE 549
550 MAINTAINING YOUR VEHICLE Rear Lamp Bar ID Marker (Dual Rear Wheels) — If Equipped
1. Loosen the two screws and the housing to gain access to the bulb sockets.
2. Turn the socket 1⁄4 turn counterclockwise to access the bulb. 3. Pull the bulb straight out from the socket. 4. Reverse the procedure for installation of the bulbs and housing.
Side Marker Lamps (Dual Rear Wheels) — If Equipped
MAINTAINING YOUR VEHICLE 551
2. Pull the entire assembly from the fender. 3. Turn the socket 1⁄4 turn counterclockwise and remove from assembly to access the bulb. 4. Pull the bulb straight out from socket. 5. Reverse the procedure for installation of the bulbs and housing.
1. Push rearward on the side marker lamp assembly.
552 MAINTAINING YOUR VEHICLE FLUID CAPACITIES
Fuel (Approximate) 1500 Regular Cab Shortbed/Crew Quad Cab Models 1500 Regular Cab Longbed/Crew Quad Cab Models (Optional) 2500/3500 Shortbed Models 2500/3500 Longbed Models Engine Oil with Filter 3.7L Engine (SAE 5W-20, API Certified) 4.7L Engine (SAE 5W-20, API Certified) 5.7L Engine (SAE 5W-20, API Certified) 5.7L Engine (SAE 5W-30, API Certified). For 2500/ 3500 trucks operating under a gross combined weight rating greater than 14,000 lbs (6 350 kg).
U.S.
26 Gallons
32 Gallons
34 Gallons 35 Gallons
5 Quarts 6 Quarts 7 Quarts 7 Quarts
Metric
98 Liters
121 Liters
129 Liters 132 Liters
4.7 Liters 5.7 Liters 6.6 Liters 6.6 Liters
Cooling System 3.7L Engine (MOPAR威 Antifreeze/Coolant 5
Year/100,000 Mile Formula or equivalent) 4.7L Engine (MOPAR威 Antifreeze/Coolant 5
Year/100,000 Mile Formula or equivalent) 5.7L Engine — 1500 Models (MOPAR威 Antifreeze/ Coolant 5 Year/100,000 Mile Formula or equivalent) 5.7L Engine — 2500/3500 Models (MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula or equivalent) 5.7L Engine — 2500/3500 Models w/Heavy Duty (MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula or equivalent)MAINTAINING YOUR VEHICLE 553
U.S.
14 Quarts
14 Quarts
16 Quarts
Metric
13 Liters
13 Liters
15 Liters
18.7 Quarts
17.7 Liters
19.2 Quarts
18.2 Liters
554 MAINTAINING YOUR VEHICLE FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant
Engine Oil
Engine Oil – For 2500/3500 trucks operating un- der a gross combined weight rating greater than 14,000 lbs/(6,350 kg.) Engine Oil Filter Spark Plugs – 3.7L Engine Spark Plugs – 4.7L Engine
Spark Plugs – 5.7L Engine Fuel Selection – 3.7L and 4.7L Engines Fuel Selection – 5.7L Engine
Fluid, Lubricant, or Genuine Part MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Use API Certified SAE 5W-20 Engine Oil, meeting the re- quirements of Chrysler Material Standard MS-6395. Refer to your engine oil filler cap for correct SAE grade. Use API Certified SAE 5W-30 Engine Oil, meeting the re- quirements of Chrysler Material Standard MS-6395. Refer to your engine oil filler cap for correct SAE grade. MOPAR威 Engine Oil Filter or equivalent. ZFR6F-11G (Gap 0.043 in [1.09 mm]) Upper Bank — FR8TE2 (Gap 0.039 in [.99 mm]) Lower Bank — FR8T1332 (Gap 0.051 in [1.30 mm]) LZFR5C–11 (Gap 0.043 in [1.09 mm]) 87 Octane 87 Octane Acceptable - 89 Octane Recommended
Chassis Component Automatic Transmission
Transfer Case
Transfer Case – NVG 246 Only Front Axle – 1500 Four-Wheel Drive Models Rear Axle – 1500 Models
Front and Rear Axle – 2500/3500
Models Brake Master CylinderPower Steering Reservoir
MAINTAINING YOUR VEHICLE 555
Fluid, Lubricant, or Genuine Part MOPAR威 ATF+4威 Automatic Transmission Fluid or equivalent licensed ATF+4威 product. MOPAR威 ATF+4威 Automatic Transmission Fluid or equivalent licensed ATF+4威 product. MOPAR威 NVG 246 Automatic Transmission Fluid or equivalent. GL-5 SAE 75W-90 (MS-9763) or equivalent.
MOPAR威 Synthetic Gear Lubricant SAE 75W-140 (MS-8985). Limited-Slip Rear Axles require the addition of 118 ml (4 oz.) MOPAR威 Limited Slip Additive or equivalent. Synthetic, GL-5 SAE, 75W-90 or equivalent. Limited-Slip 10.5/11.5 inch Rear Axles Limited slip additive is not required. MOPAR威 DOT 3 and SAE J1703 or equivalent. If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. MOPAR威 Power Steering Fluid +4, MOPAR威 ATF+4威 Automatic Trans- mission Fluid or equivalent licensed ATF+4威 product.
MAINTENANCE SCHEDULES
CONTENTS
䡵 Emissions Control System Maintenance . . . . . . 558
䡵 Maintenance Schedule . . . . . . . . . . . . . . . . . . 558▫ Required Maintenance Intervals . . . . . . . . . . 560
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558 MAINTENANCE SCHEDULES EMISSIONS CONTROL SYSTEM MAINTENANCE The Scheduled Maintenance services listed in bold type must be done at the times or mileages specified to ensure the continued proper functioning of the emissions control system. These and all other maintenance services in- cluded in this manual, should be done to provide best vehicle performance and reliability. More frequent main- tenance may be needed for vehicles in severe operating conditions, such as dusty areas and very short trip driving. Inspection and service should also be done anytime a malfunction is suspected. NOTE: Maintenance, replacement or repair of the emis- sions control devices and systems on your vehicle may be performed by any automotive repair establishment or individual using any automotive part that has been certified pursuant to U.S. EPA or in the State of Califor- nia, California Air Resources Board regulations.
Information Center
MAINTENANCE SCHEDULE The oil change indicator system will remind you that it is time to take your vehicle in for scheduled maintenance. On Electronic Vehicle (EVIC) equipped vehicles, “Oil Change Required” will be dis- played in the EVIC and a single chime will sound, indicating that an oil change is necessary. On Non-EVIC equipped vehicles, “Change Oil” will flash in the instrument cluster odometer and a single chime will sound, indicating that an oil change is necessary. Based on engine operation conditions the oil change indicator message will illuminate. This means that ser- vice is required for your vehicle. Have your vehicle serviced as soon as possible, within the next 500 miles (805 km).
NOTE: • The oil change indicator message will not monitor the time since the last oil change. Change your vehicle’s oil if it has been six months since your last oil change even if the oil change indicator message is NOT illuminated. • Change your engine oil more often if you drive your • Under no circumstances should oil change intervals exceed 6,000 miles (10,000 km) or six months, which- ever comes first.
vehicle off-road for an extended period of time.
Your authorized dealer will reset the oil change indicator message after completing the scheduled oil change. If a scheduled oil change is performed by someone other than your authorized dealer, the message can be reset by referring to the steps described under “Electronic Vehicle Information Center (EVIC)/Oil Change Required” in
MAINTENANCE SCHEDULES 559
“Understanding Your Instrument Panel” or under “In- strument Cluster Description/Odometer/Trip Odom- eter” in “Understanding Your Instrument Panel” for further information. At Each Stop for Fuel • Check the engine oil level about five minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. • Check the windshield washer solvent and add ifrequired.
Once a Month • Check tire pressure and look for unusual wear or
damage.
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560 MAINTENANCE SCHEDULES
as required.
• Inspect the battery and clean and tighten the terminals • Check the fluid levels of the coolant reservoir, brake master cylinder, power steering and transmission and add as needed. • Check all lights and other electrical items for correct
operation.
At Each Oil Change • Change the engine oil filter. • Inspect the brake hoses and lines.
CAUTION!
Failure to perform the required maintenance items may result in damage to the vehicle.
Required Maintenance Intervals
** Vehicle’s built with the 4.7L engine are NOTE: equipped with sixteen spark plugs. One set is located on the top of the engine under the coils and the second set is located on the side of the engine. The spark plugs located under the coils are a standard plug and must be changed every 48,000 miles (80 000 km). The spark plugs located on the side of the engine are a premium plug and must be changed every 96,000 miles (160 000 km).
6,000 Miles (10,000 km) or 6 Months Maintenance Service Schedule ❏ Change the engine oil and engine oil
filter.
❏ Rotate the tires. ❏ Lube the front drive shaft fitting (2500/3500 (4x4) models only).
MAINTENANCE SCHEDULES 561
12,000 Miles (20,000 km) or 12 Months Maintenance Service Schedule ❏ Change the engine oil and engine oil filter. ❏ Rotate the tires. ❏ If using your vehicle for any of the following: Dusty or off-road conditions. Inspect the
engine air cleaner filter; replace if necessary.
❏ Lube the front drive shaft fitting (2500/3500 (4x4) models only). ❏ Inspect the brake linings, replace if necessary. ❏ Inspect the CV joints. Perform the first inspection at 12,000 miles (20 000 km) or
12 months.
❏ Inspect exhaust system. Perform the first inspection at 12,000 miles (20 000 km) or
12 months.
❏ Inspect the front suspension, tie rod ends and boot seals for cracks or leaks and all parts for
damage, wear, improper looseness or end play; replace if necessary.
Odometer Reading
Repair Order #
Date
Dealer Code
Odometer Reading
Repair Order #
Date
Dealer Code
Signature Authorized Chrysler Dealer
Signature Authorized Chrysler Dealer
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